Wide path welding, cladding, additive manufacturing

ABSTRACT

A welding or cladding apparatus in which one or more energy beam emitters are used to generate a wide beam spot transverse to a welding or cladding path, and one or more wide feeders feed wire to the spot to create a wide welding or cladding puddle.

The present disclosure generally relates to metalworking applicationssuch as welding and cladding applications. The disclosure isparticularly suitably in hotwire welding and cladding applications.

BACKGROUND

Various welding and cladding techniques are known. Very popular is theuse of powder cladding in which a laser is used to melt a power on aworkpiece.

Hot wire welding and hot wire cladding are processes where a metalfiller or feeder wire is heated, usually resistively, by passing anelectrical current through it. The wire is typically fed in front of orbehind a high-power energy source such as a laser or plasma that furthermelts the wire material along with the base metal of the workpiece toproduce a weld or clad. Typically, the energy source produces a spot orfootprint with a diameter less than 4 mm on the workpiece.

The resistive heating of the metal filler wire reduces the amount ofheat needed for the base metal of a workpiece to which the heated wireis applied. Further, this puts most of the heat into the clad withresistive heating instead of laser beam heating so the laser beam meltsthe base metal a minimal amount Hence it reduces dilution of the cladmaterial and increases the deposition rate. Beneficially, heating up thewire can rid it of moisture, so when it enters the welding/claddingpuddle it's free of porosity, it's clean and the quality issignificantly better than cold wire.

The use of hot wire welding, such as gas tungsten arc welding (“GTAW”),also known as tungsten inert gas (“TIG”) welding, tends to be morepart-related and industry-related. For example, hot wire TIG is usedextensively in the transportation and power generation industries. It'sbig in shipbuilding, and for rebuilding turbine shafts for large powerplants. Hot wire TIG also is used in cladding very large valves such asthose for oil industry in which welders clad the inside of the valvebody with high-performance alloys.

SUMMARY

Disclosed herein are one or more inventions that allow for large surfacearea welding, cladding or additive manufacturing. This enables forgreater welding, cladding or additive metal coverage and/or fasterwelding, cladding or additive manufacturing processes.

Also disclosed are inventions welding, cladding and additivemanufacturing operations using laser beam footprints with variableenergy profiles. Variable energy profiles can provide improveddistribution of the molten filler or feeder wire.

As used herein, a metalworking operation means a welding operation, acladding operation, an additive manufacturing operation or anycombination of them. Unless specifically noted otherwise, the term“metalworking apparatus” is used generically herein and the accompanyingclaims to mean any welding apparatus, any cladding apparatus or anyadditive manufacturing apparatus that performs a metalworking operation,be it a non-hotwire welding apparatus, a hotwire welding apparatus, anon-hotwire cladding apparatus or a hotwire cladding apparatus.Similarly, unless specifically noted otherwise, the term “metalworkingprocess” is used generically to mean any welding, cladding or additivemanufacturing process be it a non-hotwire welding process, a hotwirewelding process, a non-hotwire cladding process or a hotwire claddingprocess. Further, the term “spot” is used herein to mean an area orfootprint of incidence of one or more high energy beams.

A hotwire is a filler or feeder wire that is preliminarily heated,typically resistively, during application of the wire in a metalworkingoperation. High power energy is applied to the wire, or the wire and aworkpiece, to melt the wire, or the wire and a portion of the workpiece,respectively. An additive manufacturing operation uses molten wire todeposit metal to produce products. An example of an additivemanufacturing process is what can be referred to as 3-D printingprocesses.

In an embodiment, the disclosure provides a metalworking apparatus,comprising an energy beam, preferably a laser beam, emitter and anoptical system to shape the beam to have a controlled footprint.

In an embodiment, a width of the footprint on the weld path is largerthan 4 mm. Preferably, the footprint is in a shape of a circle, arectangle, a triangle, a ring, or an ellipse.

In an embodiment, one or multiple feeder wires are fed into the widefootprint. During the wire feeding process, the wire can be fedunwaveringly into the wide footprint or fed staggeringly or waveringlysuch as in a weaving or spinning motion. In an embodiment, one ormultiple energy beams irradiate a workpiece unwaveringly with a widefootprint or staggeringly or waveringly to create a wide welding puddle.

In an embodiment, the disclosure provides a metalworking apparatus,comprising one or more energy beam emitters arranged to irradiate aworkpiece and have one or more spots of high energy incident on theworkpiece; and one or more wire feeders configured to feed one or morewires to the one or more spots and which when melted by the energy beamor beams form a wide molten metal puddle.

In an embodiment, the apparatus includes a plurality of energy beamemitters arrayed along a straight line.

In an embodiment, the width direction of the spot is orthogonal to thewelding path.

In an embodiment, the width direction of the welding puddle is at anoblique angle to the welding path.

In an embodiment, the apparatus includes two or more contiguous spots ofhigh energy incident on the workpiece.

In an embodiment, the apparatus includes a energy beam emitter whichemits a wide energy beam.

In an embodiment, the apparatus includes a plurality energy beamemitters which emit energy beams of substantially equal cross-sectionand intensity.

In an embodiment, each energy beam emitter is a laser.

In an embodiment, the apparatus includes a wire feeder configured tofeed a ribbon wire.

In an embodiment, the one or more feeders include circuitry to preheatthe one or more wires.

In an embodiment, multiple filler wires can have variable chemicalcompositions to enable control over the chemical composition of the dadsor welds.

In an embodiment, the disclosure provides a method that includesirradiating a workpiece with one or more beams of energy and creatingone or more spots of high energy incident on the workpiece; moving theworkpiece relative to the one or more spots; and feeding one or morewires to the one or more spots and forming at the one or more spots awide puddle of molten wire material, wherein, the puddle has widthgreater than a length, the puddle length extending in a first directionof the relative movement between the workpiece and the one or morespots, the width extending a second direction transverse to the firstdirection, the width being 4 mm or greater.

In an embodiment, the method includes irradiating the workpiece with anenergy beam emitter that emits an energy beam with a rectangular crosssection.

In an embodiment, the method includes irradiating the workpiece with aplurality of energy beam emitters arrayed along a line.

In an embodiment, the method includes feeding a ribbon wire to the oneor more spots.

In an embodiment, the method includes conducting a current through theone or more fillers wires to cause same to reach a semi-liquidus statewhile reach the puddle.

In an embodiment, the method includes feeding one or more fillers wiresin parallel to a single wide spot.

In an embodiment, the method includes feeding a ribbon wire to aplurality of spots arrayed along a line.

In an embodiment, the spots overlap.

In an embodiment, the beams of energy are laser beams.

In an embodiment, the disclosure provides a metalworking apparatus,comprising: one or more lasers arranged to irradiate a workpiece andhave one or more spots of high energy incident on the workpiece; one ormore wire feeders configured to feed one or more wires to the one ormore spots and which when melted by the one or more beams of energy forma wide welding puddle, the welding puddle having a width in a directiontransverse to a direction of a welding path, the width of the weldingpuddle being greater than a length of the welding puddle in thedirection of the welding path; and circuitry for preheating the wires,the width being 4 mm or greater.

These and other aspects of the embodiments are set forth below in thedetailed description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates in cross section a basic hotwire welding arrangementand process.

FIG. 2 illustrates in plan view a welding process embodying principlesof the disclosure in which multiple wires are employed.

FIG. 3 illustrates in plan view a welding process embodying principlesof the disclosure in which a wide wire ribbon is used.

FIG. 4 illustrates in plan view a welding process embodying principlesof the disclosure in which an energy spot with a rectangular footprintis used.

FIG. 5 illustrates in plan view a welding process embodying principlesof the disclosure in which an angled weld spot is used.

FIG. 6 illustrates in plan view a welding process embodying principlesof the disclosure in which adjacent, but stair-stepped welding spots areused.

FIG. 7 illustrates in plan view a welding process embodying principlesof the disclosure in which a ribbon wire is fed to a weld puddleirradiated by plural energy beams of different strengths and/ordiameters.

FIG. 8 illustrates in plan view a welding process embodying principlesof the disclosure in which multiple wires are fed from a common nozzleto a weld puddle irradiated by plural energy beam of the same ordifferent strengths and/or diameters.

FIG. 9 illustrates a control schematic for controlling plural wirefeeders and plural high energy sources.

FIGS. 10A to 10E illustrate various laser footprints that can be used toprovide a wide path in accordance with principles disclosed herein.

FIGS. 11A to 11D illustrate various relative power profiles that canexist along a cross section of a wide path footprint in accordance withprinciples disclosed herein.

FIGS. 12A to 12J illustrate further beam cross sections that can be usedto generate wide path welding, cladding, or additive manufacturingfootprints.

FIG. 13 illustrates a moving or wavering wire been feed into a wideenergy beam footprint to obtain a wide path weld, clad, or deposit.

FIG. 14 illustrates plural filler wires been feed into a path irradiatedby a moving or wavering energy beam to obtain a wide path weld, clad, ordeposit.

DETAILED DESCRIPTION

The present disclosure is herein described in detail with reference toembodiments illustrated in the drawings, which form a part hereof. Otherembodiments may be used and/or other changes may be made withoutdeparting from the spirit or scope of the present disclosure. Theillustrative embodiments described in the detailed description are notmeant to be limiting of the subject matter presented herein.

Reference will now be made to the exemplary embodiments illustrated inthe drawings, and specific language will be used herein to describe thesame. It will nevertheless be understood that no limitation of the scopeof the invention is thereby intended. Alterations and furthermodifications of the inventive features illustrated herein, andadditional applications of the principles of the inventions asillustrated herein, which would occur to one skilled in the relevant artand having possession of this disclosure, are to be considered withinthe scope of the present disclosure.

In FIG. 1 there is illustrated a hotwire laser welding process in whichone or more principles of the present disclosure can be used. Asillustrated, a metallic workpiece 10 and wire feeding nozzle/gun ortorch 12 are positioned for relative travel between them. The workpiece10 is representative of a base metal of any suitable workpiece. Thedirection of travel of the nozzle 12 relative to the workpiece 10 isindicated by arrow 14.

Note that the relative direction of travel is not necessarily linear.The workpiece 10 could rotate about a horizontal axis, for example apipe rotating about its cylindrical axis, or it could rotate about avertical axis, for example, a wheel or disc mounted and rotating in ahorizontal plane.

In process steady-state, filler wire 16 is feed out of the nozzle 12toward a molten pool or puddle 18. At the same time, the molten pool 18is subject to heating by a high energy source, in this case a focusedlaser beam 20 generated by a laser 21, that further melts the wire 16and, if a welding process, a portion of the metallic workpiece 10 (i.e.,the base metal) to form the puddle 18.

Since the workpiece 10 is moving relative to nozzle 12 and the highenergy source 20, the molten metal comprised of molten wire and, if awelding process, molten workpiece metal, exiting the incidence area ofthe high energy beam 20 cools and solidifies to form a clad layer, or ifa welding process, a weld, 22.

In this illustrative process, shielding gas 24 is also provided via thenozzle 12.

The high energy spot generated on the workpiece by the high energysource typically is about 3 mm in diameter. However, the presentdisclosure provides one or more embodiments where a wider, relative tothe direction of travel, spot is generated.

In FIG. 2, there is illustrated a welding process in which multiplewires 16 a-16 d are fed in parallel from respective nozzles 12-12 d to awide high energy spot 26. In this embodiment, the high energy beam isagain a laser beam, but the footprint of the spot 26 is rectangular.Further, the footprint has a width W in a direction other than thedirection of travel that is greater than that normally used for a singlewire. In the illustrated embodiment, the footprint spans a distanceorthogonal to the direction of travel that accommodates four wires.

As a result, a wide weld or deposited clad layer 28 essentially has thesame width W and can be characterized as a wide path.

As in the process of FIG. 1, in the process of FIG. 2, the wires 16 a-16b are preheated using known hotwire resistive heating techniques andshielding gas may or may not be employed.

In accordance with principles herein, the wires 16 a-16 d can bepreheated using the same or different power levels. The use of differentindependent power levels enables independent control of the wires, andan ability to control the profile of the resultant weld or clad 28.

In accordance with other principles depicted in FIG. 3, instead of amultiple wires 16 a-16 d, a single flat ribbon 30 made of filler wirematerial may be employed. A suitable nozzle 32 is used to feed the flatribbon filler wire 30. The opening of the nozzle 32 could be oblong orflattened to better accommodate the shape of the ribbon 30. The use of asingle ribbon may provide for a more continuous deposition of fillermaterial across the welding or cladding path.

Also depicted in FIG. 3 is the use of multiple energy beams 34 a-34 d,e.g., laser beams, to generate the molten puddle. The footprints 36 a-36d of the beams are shown as overlapping to the extend necessary toprovide the most uniform overall high energy beam spot on the workpiece.Of course, independent control of the beam sources to providedifferently sized footprints and/or energy levels may enable thegeneration of different profiles in the resultant deposited weld orclad.

In FIG. 4, there is illustrated an arrangement where multiple fillerwires 40 a-40 c are fed in parallel from respective nozzles 42 a-42 c toa rectangular footprint of a high energy beam spot 44. In thisarrangement, the high energy beam source is again a laser 46, and anoptical system 48 is used to create the rectangular footprint. Suchoptical systems are known as homogenizers, and both reshape the beaminto a rectangular shape, usually a square shape, and create ahomogenous distribution of the energy of the beam across its footprint.One example is that provided by Laserline GmbH located inMülheim-Karlich, Germany.

Further, a laser beam emitter and optical system combination effectiveto produce such a controlled shape is available from Coherent, Inc.which markets such lasers as using its “top hat” technology. In thistechnology, two Powell lenses are used. A Powell lens is an asphericcylindrical lens that purposefully aberrates a collimated Gaussian inputbeam so that the energy is efficiently redistributed from the beamcenter to the edges in the far field.

In accordance with principles disclosed herein, advantageously, theresultant footprint may have a non-uniform distribution of energy for animproved resultant deposited weld or clad. In that regard, with anenergy profile where the center of the footprint is cooler than edges ofthe footprint, e.g., a profile with a linear, geometrical or exponentialchange in the energy level proceeding from the center to the edges ofthe footprint, the molten wire will tend to better flow or distribute tothe edges of the footprint, and this can result in a more uniform weld,clad or deposit.

In accordance with principles disclosed herein, the foregoing can beaccomplished, e.g., in the Laserline optics. In these optics, the lensor lenses comprise a multitude of reflective surfaces at differentangles. In the manufacture of the lens or lenses, these surfaces,including their angles, can be customized. With such customization anenergy distribution profile can be specified and implemented, whilemaintaining an overall rectangular footprint.

With the rectangular shaped footprint, the shape can be square ornon-square, and footprints of different sizes can be generated. Somesuitable footprints measure 6 mm by 6 mm, 10 mm by 5 mm, or 12 mm by 6mm. The achievable measurements are determined by the energy of thelaser beam and the settings of the optical system.

In FIGS. 10A to 10E there are other laser footprints described and inFIGS. 11A to 11D there are various energy profiles described.

With a rectangular footprint, metal deposition rates of about 25lbs./hour have been achieved. This contrasts with deposition rates ofonly 8 lbs./hour to 10 lbs./hour in conventional apparatus. These higherdeposition rates are achieved due to the higher surface areas to whichthe metal can flow when be deposited.

If FIG. 5, there is illustrated an arrangement in which multiple fillerwires 50 a-50 e are fed out of respective nozzles 52 a-52 e torespective high energy spots 54 a-54 e created by high energy beams 56a-56 e. Although the footprints of the spots 54 a-54 e are shown aselliptical, they can be any suitable shape.

As also illustrated, the footprints 54 a-54 e are positioned to providean overall “V” shape with the middle of the V in the middle of thedeposition path, and the legs of the V extending toward a trailing edgeof the path. Thus the middle of the V forms a leading point for thepath.

In FIG. 6, there is illustrated an arrangement in which multiple fillerwires 60 a-60 d are feed out of respective nozzles 62 a-62 d torespective high energy spots 64 a-64 d created by high energy beams 66a-66 d. In this arrangement, the spots are arranged stair-stepped withspots 64 a and 64 b define a first line and spots 64 c and 64 d define asecond line that is offset from the first line along the depositionpath.

In FIG. 7, there is illustrated an arrangement in which a ribbon fillerwire 70 is feed out of a nozzle 72 to a line of high energy spots 74a-74 d created by respective high energy beams 76 a-76 d. In thisarrangement, the points of incidence of the high energy beams arearrayed along a straight line that is orthogonal to the deposition path.The individual footprints of the beams vary in size and/or the energylevels of the beams can vary to provide a varied profile to the weld orclad. In this embodiment, the beams are shown to varying in a descendingor increasing order, however, any order could be used.

In FIG. 8, there is illustrated an arrangement in which a plurality offiller wires 80 a-80 d are fed out of a wide nozzle 82 to a line of highenergy spots 84 a-84 d created by respective high energy beams 86 a-86d. In this arrangement, the points of incidence of the high energy beamsare arrayed along a straight line that is orthogonal to the depositionpath. The energy beams can be of the same energy level or differentenergy levels. The individual footprints of the beams can be the same orvary in size. Again, varying the energy levels and/or the footprints canvary the deposition profile as discussed above.

In the preceding embodiments, the multiple spots under determinablecircumstances by a single elongate spot as described in connection withFIG. 4. Further, the multiple spots can be allowed to overlap, asdescribed in connection with FIG. 3. The degree of overlap would bedetermined, at least in part, by the energy level profiles of the spots.

In FIG. 9, there is illustrated a block diagram schematic of a controlarrangement for controlling plural wire feeders F₁, F₂ . . . F_(n) andplural high energy sources EB₁, EB₂ . . . EB_(m). The feeders and energysources may or may not be equal in number.

As illustrated, control circuitry 900 includes a processor or processingcore 902 and memory 904 storing instructions executed by the processoror processing core 902. The processor/processing core 902 is incommunication with an input/output module 906 comprised of one or moresub-modules that generate the necessary control signals and that receiveany feedback signals from the wire feeders and high energy sources. Theinput/output module 906 in turn is in communication via suitable cablesor links 908 and 910 to the various feeders and high energy sources,respectively. With respect to the wire feeders in particular, thesignals and commands can include appropriate signals for controllingpreheating of the wires, if appropriate. In this arrangement, thefeeding of a desired number of wires can be controlled as well anappropriate number of high energy sources to effect the deposition ofmetal in a desired profile, such as those described above.

In FIGS. 10A to 10E there are illustrated various laser/high energyfootprints or spots that might be achieved by appropriate customizationof the Laserline optics discussed above. In addition to a square shape,the shapes can be a triangular shape as shown in FIG. 10A, diamond shapeor the combination of two triangular footprints as shown in FIG. 10B, ahouse or baseball home plate shape or the combination of a rectangularfootprint and a triangular footprint as shown in FIG. 10B, an arrowheadshape of another combination of two triangular footprints as shown inFIG. 10D. FIG. 10E shows another rectangular shape of the combination oftwo or more rectangular footprints. In each of FIGS. 10A to 10E there isshown a midline A-A for the resulting overall footprint along which therelative direction of travel lies. Further, there is illustrate a crosssection line B-B useful for discussing power profiles in connection withFIGS. 11A to 11D.

In FIGS. 11A to 11D, there are shown various energy distributionprofiles that can be across the cross sections B-B of the laser/highenergy footprints, the profile selected being dependent upon the desiredresult. In FIG. 11A there is illustrated a profile that is generallyellipsoid and symmetric about the midline A-A. In FIG. 11A, power islower at the midline that at the outer edges of the footprint.

In FIG. 11B there is illustrated a profile that is generally linearabout each side of midline A-A, with power at the midline being lowerthan power at the edges of the footprint. Since the power profiles aresymmetric about the midline A-A, and with linear slopes on each side ofthe midline, the overall shape is a “V” shape.

In FIG. 11C, there is illustrated a profile that also is generallyellipsoid and symmetric about the midline A-A, but is inverted withrespect to the profile in FIG. 11A. Thus the overall impression is thatof an inverted “U” shape, where power is greater at the midline than atthe edges of the footprint.

In FIG. 11D, there is illustrated a profile that is inverted withrespect to the profile of FIG. 11B. In this profile power is greater atthe midline and lower and the edges. Due to the symmetrical linearsloping of the power distribution from the midline, the profile has anoverall shape of a Caret symbol.

As can be appreciated, the different profiles that might be used arelimited only by the implementing technology. Thus, these profiles aremeant only to be representative and not limiting. Similarly, thefootprints that might be created are also limited only by theimplementing technology. Thus, the illustrated footprints are meant onlyto representative and not limiting.

In FIGS. 12A to 12J further beam cross section are shown. FIG. 12A showsan ellipse shape with an energy profile that proceeds from a relativelyhigher energy center portion to a lower energy out portion. FIG. 12Bshows a wide rectangular shape with an energy profile that proceeds froma relatively higher energy center portion to a lower energy out portion.FIG. 12C shows a square shape with an energy profile that proceeds froma relatively higher energy center portion to a lower energy out portion.FIG. 12D shows a square shape with two relatively higher energy edges onopposite sides of the square shape. FIG. 12E shows circular ring shape.FIG. 12F shows a circular shape with an energy profile that proceedsfrom a relatively higher energy center portion to a lower energy outportion. FIG. 12G shows a line shape with an energy profile thatproceeds from a relatively higher energy center portion to a lowerenergy out portion. FIG. 12H shows two spaced apart circular shapes,each with an energy profile that proceeds from a relatively higherenergy center portion to a lower energy out portion. FIG. 12I shows aliner shape with two pinpoint high energy spots along the linear shape.FIG. 12J shows a square shape with relative high energy pinpoint spotsat the corners of the square shape and a perimeter with an energy levelhigher than that of a center of the square shape, but lower than that atthe corners of the square shape.

As mentioned above, a wide path weld, clad, or deposit can be obtainedwhere an energy spot and one or more wires are moved relative to eachother. In FIG. 13, a wire 1300 is moved in a wavering fashion or in aspiral fashion so as to moving along the width dimension of a wide (inthis illustration, rectangular) energy beam spot 1302. In this manner,only one wire need be feed to the beam spot to obtain a wide path weld,clad, or deposit of the melted wire. In FIG. 14, the opposite occurs. InFIG. 14, plural wires 1400 are fed unwaveringly onto a weld, clad, ordeposit path irradiated by a moving or wavering energy beam spot 1402.In this way, a wide path weld, clad, or deposit can be obtained withonly a small beam spot, and wire moving mechanisms are not needed.

Those of ordinary skill in the art will easily understand how theprinciples above are employed in welding, cladding and additivemanufacturing operations and apparatus to provide wider metaldepositions and varied deposition profiles, as desired.

The preceding description of the disclosed embodiments is provided toenable any person skilled in the art to make or use the presentinvention. Various modifications to these embodiments will be readilyapparent to those skilled in the art, and the generic principles definedhere may be applied to other embodiments without departing from thespirit or scope of the invention. Thus, the present invention is notintended to be limited to the embodiments shown here but is to beaccorded the widest scope consistent with the following claims and theprinciples and novel features disclosed here.

What is claimed is:
 1. A metalworking apparatus, comprising: two or moreenergy beam emitters arranged to irradiate a workpiece with two or morespots of high energy incident on the workpiece; a first wire feederconfigured to feed a first wire to the two or more spots and which whenmelted by an energy beam of the two or more energy beams form a weldingpuddle; a second wire feeder configured to feed a second wire to thewelding puddle, the second wire applied to the welding puddle adjacentto the first wire in a direction transverse to the welding path; anoptical system configured to shape the one or more beams of energy tovary an intensity of the one or more spots of high energy incident onthe workpiece; and circuitry for controlling the two or more energy beamemitters, the first and second wire feeders, and the optical system, thecircuitry to: control the two or more energy beam emitters to emit eachspot of the two or more spots having a width in a direction transverseto a direction of a welding path; and control the two or more energybeam emitters to focus the two or more spots on the workpiece to beadjacent or to overlap on the workpiece, the cumulative width of the twoor more spots on the workpiece being greater than a length of the two ormore spots in the direction of the welding path.
 2. The apparatus ofclaim 1, comprising a plurality spots of the two or more spotscontinuously arrayed along a straight line.
 3. The apparatus of claim 2,wherein the width direction of the two or more spots is orthogonal tothe welding path.
 4. The apparatus of claim 2, wherein the widthdirection of the two or more spots is at an oblique angle to the weldingpath.
 5. The apparatus of claim 1, wherein the cumulative width of thetwo or more spots is at least 4 mm.
 6. The apparatus of claim 1, whereinthe one or more energy beam emitters comprises a single energy beamemitter which emits a wide energy beam or a moving energy beam to createthe welding puddle.
 7. The apparatus of claim 1, comprising a pluralityenergy beam emitters which emit energy beams of equal cross-section andintensity.
 8. The apparatus of claim 1, wherein the one or more energybeam emitters comprises a plurality energy beam emitters which emitenergy beams with different energy intensities.
 9. The apparatus ofclaim 1, wherein each energy beam emitter of the one or more energy beamemitters is a laser.
 10. The apparatus of claim 5, wherein an intensityof the high energy incident on the workpiece varies across the one ormore spots.
 11. The apparatus of claim 1, wherein the optical system isconfigured to shape the one or more spots to create a footprint on theworkpiece.
 12. The apparatus of claim 11, wherein the optical system isconfigured to control one or more of an energy distribution or a size ofthe one or more spots on the workpiece.
 13. The apparatus of claim 1,wherein the circuitry is further configured to control the two or moreenergy beam emitters to vary an intensity of the high energy incident onthe workpiece across the cumulative width of the one or more spots. 14.A metalworking apparatus, comprising: one or more lasers arranged toirradiate a workpiece with one or more beams of energy forming one ormore spots of high energy incident on the workpiece; an optical systemconfigured to shape the one or more beams of energy to vary an intensityof the one or more spots of high energy incident on the workpiece; afirst wire feeder configured to feed a first wire to the one or morespots and which when melted by the one or more beams of energy form awelding puddle; a second wire feeder configured to feed a second wire tothe welding puddle, the second wire applied to the welding puddleadjacent to the first wire, each spot of the one or more spots having awidth in a direction transverse to a direction of a welding path and alength along the direction off the welding path, a cumulative width ofthe one or more spots being greater than a length of the one or morespots; and circuitry for controlling each laser of the one or morelasers, the optical system, and the first and second wire feeders.